Air conditioner and an air conditioner housing

ABSTRACT

An air conditioner includes a housing, at least one evaporator air mover and at least one condenser air mover, an evaporator positioned within the housing in front of the evaporator air mover, and a non-linear condenser positioned within the housing behind the evaporator air mover. The condenser is arranged such that a body of the condenser is substantially perpendicular to the body of the evaporator.

CROSS REFERENCE TO RELATED APPLICATION(S)

This application claims the benefit of Provisional Application No. 62/505,448, filed on May 12, 2017, which is incorporated herein by reference as if fully set forth.

FIELD OF INVENTION

This application is generally related to air conditioning systems and devices, and more particularly related to an air conditioning and fan system that may be easily and safely mounted.

BACKGROUND

Air conditioning systems are in widespread use in homes, offices, and other buildings to cool the space in warm weather, circulate air, and control humidity. Existing air conditioning systems range from large central air conditioning systems with the capacity for cooling an entire building or home, to split or ductless air conditioning systems mounted through a wall in a home or hotel, to more portable and less permanent solutions such as standalone portable air conditioners in a mobile unit having a hose vent, and window air conditioners that are mounted in a window and removed during the cooler months of the year. Portable air conditioners, especially window air conditioners, are very popular for apartments and other rental properties, temporary or student housing, older homes without a central air conditioning system, as well as buildings in cooler climates that only require cooling occasionally, as such air conditioning units are generally cost-effective, can be installed, removed, and stored when not in use, and can be moved based on the owner's needs.

Despite the popularity of window air conditioners and the large market for them, there exist a number of disadvantages in existing window air conditioning units. These disadvantages including the significant size and weight of current window air conditioners, which makes installation difficult and potentially dangerous, especially for users attempting to install a unit by themselves. Existing window air conditioners often weigh between 50 to 120 pounds, range between 14″-48″ in width, range between 18″-34″ in height, and range between 18″-36″ in depth. Accordingly, these existing units are often too large and heavy for an individual to carry and move safely and comfortably. In addition, installation of a window air conditioner typically requires lifting the unit and aligning it in a window opening, and then holding the unit in place until it is sufficiently secured, which can be made significantly more difficult by the size and weight of existing units. Removing a window air conditioner from a window is similarly demanding, causing many users to keep their window air conditioners installed even during colder weather such as the winter months, which leads to a significant loss of heat from the home and higher energy bills. The large dimensions of existing window air conditioners may not fit smaller windows, and large interior space with only one or a few windows that require particularly high levels of cooling capacity relative to the available window area are not well served by existing units. Furthermore, the large form factor of existing window air conditioners blocks much of the view and light from the window, and is commonly regarded as an eye sore from both inside and outside of the building. The visual property of the frontal, visible area of the window air conditioner is a significant driver of consumer perception of the product. Existing window air conditioners also produce a large amount of noise during operation, and do not offer an efficient air circulation option to bring in fresh air from outside without utilizing all of the fans in the unit, which increases power consumption and noise.

In addition to the limitation discussed above, energy efficiency has become a primary goal for air conditioning systems, driven by government regulation and consumer demand for lower operating costs. A significant contributor to high energy efficiency is the performance of the condenser heat exchanger. The condenser heat exchanger takes superheated refrigerant from the compressor, and uses air, generally driven by a fan to remove heat from the refrigerant until said refrigerant condenses to a liquid, transferring the latent enthalpy of the fluid to the air source. A suitable heat exchanger will allow the refrigerant to dense at a temperature very near the temperature of the source air as it leaves the heat exchanger. A suitable heat exchanger will also allow a significant amount of air to flow over the heat exchanger surfaces, which reduces the exit temperature of the air. The lower temperature correspondingly reduces the pressure that the compressor must overcome to achieve complete condensing of the working refrigerant.

In the case of a typical air conditioning system, the evaporator from the indoor air source is also a source of condensed water resulting from the dehumidifying action of the cold evaporator heat exchanger. This condensate water contains a significant source of enthalpy due to the energy required to vaporized water and may be the result of approximately 20% of the total capacity of the system. This enthalpy, in addition to the condenser source air, can be used to further reduce the temperature of the condenser heat exchanger. These two sources of refrigeration cooling must be leveraged to achieve the modern energy efficiency standards demanded by governments and consumers alike.

A low-profile window air conditioner.

Given the disadvantages discussed above and the prevalence of window air conditioners worldwide, a need exists for an air conditioning system that has an aesthetically pleasing form that make efficient use of the available space within the housing and has high efficiency, low noise, yet an effective cooling system, and, when desired, can be easily installed, uninstalled, moved, and stored. A need further exists for a compact low profile window air conditioner that is visually less obtrusive, and allows for a better view out of the window, a significant factor in homes where the natural light entering the room is a factor in the quality of life of the room's inhabitants. A need further exists for an air conditioning system that allows for a compact low profile window air conditioner where the frontal, visible area of the air conditioner is reduced, while achieving increased efficiency of its heat exchangers without merely increasing the front face area of the heat exchanger, as doing so would similarly increase the visual front area of the heat exchanger and prevent the air conditioner from having a slim profile with a reduced visual frontal area.

SUMMARY

The present solution to the prior art provides an air conditioner having components in a space efficient assembly, a housing that facilitates that space efficient assembly, and a uniquely shaped condenser that increases efficiency without sacrificing the compact visual profile of the air conditioner. The condenser is non-linear and positioned within the housing of the air conditioner behind an evaporator and at least one evaporator air mover, and arranged such that a body of the condenser is substantially perpendicular to a body of the evaporator. The body of the condenser may be formed to be C-shaped to conform to the shape of at least one condenser air mover, and to approximate the perimeter of the air conditioner.

The present solution also provides a non-linear condenser for an air conditioner, the condenser having a housing with a major axis, a plurality of coils positioned in the denser housing for guiding a flow of refrigerant. The housing of the condenser is at least partially curved along the major axis.

The present solution also provides a method of dissipating heat in a condenser of an air conditioner. The method includes the steps of providing an air conditioner having an evaporator, at least one fan, and a condenser positioned downstream of the fan between the fan and evaporator. The method further includes the steps of forming a water condensate via the evaporator, directing the water condensate to the at least one fan, and dispersing the water condensate onto the condenser via the fan.

BRIEF DESCRIPTION OF THE DRAWINGS

The following detailed description of the preferred embodiments of the present application will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there is shown in the drawings embodiments that are presently preferred. It should be understood, however, that the inventions are not limited to the precise arrangements shown in the drawings.

FIG. 1 is a front perspective view of an embodiment of a low-profile air conditioner;

FIG. 2 is a back perspective view of the air conditioner shown in FIG. 1;

FIG. 3A is another back perspective view of the air conditioner shown in FIG. 1;

FIG. 3B is a back perspective view of an alternate embodiment of the air conditioner shown in FIG. 1;

FIG. 4 is cross-sectional view of the air conditioner shown in FIG. 1;

FIG. 5 is another cross-sectional view of the air conditioner shown in FIG. 1, taken across two different planes;

FIG. 6 is another cross-sectional view of the air conditioner shown in FIG. 1, with certain portions of the housing and other components removed;

FIG. 7 is a top perspective view of the air conditioner shown in FIG. 1, with certain portions of the housing and heat exchangers removed;

FIG. 8 is another cross-sectional view of the air conditioner shown in FIG. 1, with certain portions of the housing and other components removed;

FIG. 9 another cross-sectional view of the air conditioner shown in FIG. 1, with certain portions of the housing and other components removed;

FIG. 10 is a bottom perspective view of the air conditioner shown in FIG. 1, with certain portions of the housing and heat exchangers removed;

FIG. 11 is a top plan view of the air conditioner shown in FIG. 1, with certain portions of the housing and heat exchangers removed;

FIG. 12 is a top perspective view of the air conditioner shown in FIG. 1, with certain portions of the housing, heat exchangers, and ducting removed, as well as a cross-sectional of the front centrifugal fans removed;

FIG. 13 is a top front perspective view of the air conditioner shown in FIG. 1, with certain portions of the housing, heat exchangers, and ducting removed;

FIG. 14 is a top perspective view of the air conditioner shown in FIG. 1, with certain portions of the housing removed, and a cross-section taken across two different planes;

FIG. 15 is another cross-sectional view of the air conditioner shown in FIG. 1, with certain portion of the housing removed;

FIG. 16 is a side view of the air conditioner shown in FIG. 1, with certain components removed to illustrate the main refrigeration components;

FIG. 17 is top perspective view of the air conditioner shown in FIG. 1, with certain components removed to illustrate the main refrigeration components;

FIG. 18 is a bottom perspective view of the air conditioner shown in FIG. 1, with certain components removed to illustrate the main refrigeration components;

FIG. 19 is another top perspective view of the air conditioner shown in FIG. 1, with certain components removed to illustrate the main refrigeration components;

FIG. 20 is a top plan view of the air conditioner shown in FIG. 1, with certain components removed to illustrate the main refrigeration components;

FIG. 21 is a bottom perspective view of the air conditioner shown in FIG. 1, with certain components removed to illustrate the main refrigeration components;

FIGS. 22A and 22B are cross-sectional views comparing the air conditioner shown in FIG. 1 with an alternate embodiment of a low profile air conditioner that utilizes a different type fan;

FIG. 23 are cross-sectional views comparing additional alternate fan embodiments that may be utilized with the air conditioner shown in FIG. 1;

FIG. 24 is a top plan view of the air conditioner shown in FIG. 1, with certain portions of the housing and manifold removed to illustrate the various components along with part numbers;

FIG. 25 is a top perspective view of the air conditioner shown in FIG. 1, with certain components removed to illustrate the main heat exchanger and fan components;

FIG. 26 is a bottom perspective view of the air conditioner shown in FIG. 25;

FIG. 27 is a cross-sectional view of the air conditioner shown in FIG. 25;

FIG. 28 is another cross-sectional view of the air conditioner shown in FIG. 25;

FIG. 29 is a front perspective view of the air conditioner shown in FIG. 25, with additional manifold components removed;

FIG. 30 is a back perspective view of the air conditioner shown in FIG. 29;

FIG. 31 is a bottom perspective view of the air conditioner shown in FIG. 29;

FIG. 32 is a top perspective view of an alternate embodiment of the air conditioner, with certain components removed to illustrate the heat exchanger and fan arrangements;

FIG. 33 is a bottom perspective view of the air conditioner shown in FIG. 32;

FIG. 34 is a cross-sectional view of the air conditioner shown in FIG. 32;

FIG. 35 is a top perspective view of the air conditioner shown in FIG. 32, with the condenser removed to illustrate the fan arrangements;

FIG. 36 is a front perspective view of the air conditioner shown in FIG. 32;

FIG. 37 is a right cross-sectional view of the air conditioner shown in FIG. 36;

FIG. 38 is a top perspective view of the air conditioner shown in FIG. 32, with part of the housing shown;

FIG. 39 is a cross-sectional view of the air conditioner shown in FIG. 38;

FIG. 40 is another cross-sectional view of the air conditioner shown in FIG. 32, taken across two different planes with certain portions of the housing removed;

FIG. 41 is another cross-sectional view of the air conditioner shown in FIG. 32, taken across two different planes with the housing shown;

FIG. 42 is another cross-sectional view of the air conditioner shown in FIG. 32, with the housing shown;

FIG. 43 is a top plan view of the air conditioner shown in FIG. 32 with certain portions of the housing removed;

FIG. 44 is a top perspective view of the air conditioner shown in FIG. 32, with the fan components removed;

FIG. 45 is a bottom perspective view of the air conditioner shown in FIG. 32, with the fan components removed;

FIG. 46 is a top perspective view of the air conditioner shown in FIG. 32, with the fan components and certain portions of the housing and other components removed, illustrating airflows; and

FIG. 47 is a side cross-sectional view of the air conditioner shown in FIG. 32, illustrating airflows.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Certain terminology is used in the following description for convenience only and is not limiting. The words “front,” “back,” “top,” “bottom,” “inner,” “outer,” “upper,” “lower,” “internal,” and “external” designate directions in the drawings to which reference is made. The words “upward,” “downward,” “above,” and “below” refer to directions towards a higher or lower position from the parts referenced in the drawings. The words “inward” and “outward” refer to directions towards an inner or outer portion of the element referenced in the drawings. The words “clockwise” and “counterclockwise” are used to indicate opposite relative directions of rotation, and may be used to specifically refer to directions of rotation about an axis in accordance with the well-known right hand rule. Additionally, the terms “a” and “one” are defined as including one or more of the referenced item unless specifically noted otherwise. A reference to a list of items that are cited as “at least one of a, b, or c” (where a, b, and c represent the items being listed) means any single one of the items a, b, or c, or combinations thereof. The terminology includes the words specifically noted above, derivatives thereof, and words of similar import.

The present application includes a description of a compact low profile air conditioner which more efficiently utilizes given space by including a pair of air movers and a centrally-located compressor, and further addresses the issues faced by traditional heat exchangers and efficiency limitations of known air conditioner units by utilizing a unique C-shaped condenser heat exchanger design. The C-shaped condenser is arranged so that its body is substantially perpendicular to the body of the evaporator heat exchanger, such that the condenser in conjunction with the rest of the air conditioner components and body forms an enclosed volume in which air driven through the back axial fans can more effectively be used to cool the heat exchanger and achieve higher flowrates and energy efficiency.

One of ordinary skill in the art will appreciate that there are many different types of compressors, including without limitation rotary compressors, piston compressors, and electrolytic compressors, any of which may be used with the present air conditioner. Furthermore, a variety of coolants having the requisite heat transfer characteristics may be used in the present air conditioner, including without limitation coolants that undergo phase transitions as it circulates throughout the system, which are common known as refrigerants. In an embodiment of the present air conditioner where a thermoelectric heat pump is used in place of the compressor, the coolant does not circulate between the evaporator and the condenser, but rather is separately contained in the evaporator and the condenser individually, as will be described in detail below. For purposes of the present application, the reference to a “refrigerant” is used for convenience only, and does not limit the specific coolant that may be used to a known AC refrigerant or a coolant that undergoes phase transitions, and instead may refer broadly to any coolant or heat transfer fluid that is capable of being circulated to transfer heat between components of the present air conditioner 10, including coolants that keep its phase or the use of solid materials as coolants.

FIGS. 1 through 5 show exemplary components of the present low profile air conditioner 10 arranged to provide a more compact arrangement of parts, including the unique condenser design, which in combination enables the use of a housing with a smaller exterior envelope and visual frontal area. In an exemplary embodiment, the air conditioner 10 includes a compressor 12, an accumulator 14, a condenser 16, and an evaporator 18 arranged inside of a compact housing 20. The compressor 12 may be centrally located in the housing 20 of the air conditioner 10 and be connected to the condenser 16 and evaporator 18 by piping 22 (some of the piping omitted for ease of view).

As will be described, the housing 20 includes a face plate 30 which may be located adjacent to and/or form part of a room air intake grate 34 through which air from inside of the room or building to be cooled may be drawn into the internal cavity of the housing. The room air intake grate 34 may also be referred to as the “evaporator fan air intake” in the present application, as the air flowing through the room air intake grate is being drawn into the internal cavity of the housing 20 by the evaporator fans. The housing 20 may further include a cold air exit vent 44 through which cooled air is expelled back into the interior of the space to be cooled. The cold air exit vent 44 may also be referred to as the “evaporator fan air outlet” in the present application, as the air (whether cooled interior air or fresh external air) flowing through the cold air exist vent is being expelled out from the internal cavity of the housing by the evaporator fans. The cold air exit vent may be located at the front portion of the housing 20, such as, for example and without limitation, on a top portion of the outer surface of the housing. The housing 20 may also include one or more external air intake grates 33, which may also be referred to as “condenser fan air intakes.” The external air intake grates 33 are located at the back portion of the housing, and may further be arranged on at least one of the top portion, the bottom portion, or the sides of the outer surface of the housing. Air from an exterior of the room or building to be cooled is drawn into the internal cavity of the housing through the external air intake grates to cool the condenser 16, and then the heated external air is expelled back out to the exterior atmosphere through a hot air exit vent (also known as the “condenser fan air outlet”) located in a back plate of the housing 20.

As shown in FIGS. 1, 3, and 6, the present air conditioner 10 has a front portion that is configured to be located inside of the room to be cooled, and a back portion that is configured to be located outside of the room to be cooled, once mounted to the window opening or other receptacle for the air conditioner. A retaining strap 28 located generally in a middle portion of the air conditioner 10 may be utilized to secure the air conditioner 10 to the window opening, receptacle, or mounting apparatus, and separates the front inside portion of the air conditioner 10 from the back outside portion of the air conditioner.

If a thermoelectric heat pump is used in place of a traditional compressor 12, each of the evaporator 18 and condenser 16 may include a heat pipe containing a suitable coolant, and be thermally associated with the thermoelectric heat pump, such that the coolant within the heat pipes of the evaporator 18 and condenser 16 is being heated or cooled by the thermoelectric heat pump to transfer heat out of the interior of the room to be cooled.

The air conditioner 10 includes air movers in the form of a pair of condenser fans 24 and a pair of evaporator fans 26 which are arranged on opposing sides of the compressor 12. The condenser fans 24 are preferably axial fans or crossflow fans and the evaporator fans 26 are preferably centrifugal fans or crossflow fans. The condenser fans 24 and the evaporator fans 26 may be driven by a common motor 42 positioned respectively between each set of fans (as shown in FIG. 3).

Although centrifugal fans are known in air conditioners, known window air conditioners usually are driven by a single motor in the prior art fan assembly. By way of contrast, the present air conditioner 10 utilizes two separate sets of evaporator fans 26 and condenser fans 24, each driven by a separate motor 42 along a rotational axis that is aligned with the longitudinal direction Y along the length (i.e. the depth) of the housing, thus allowing the compressor 12 to be uniquely positioned between the two sets of fans.

The evaporator fans 26 need high pressure but less overall airflow, as the goal of the evaporator fans 26 is to pull air through the face plate 30 and/or room air intake grate 34, possibly through a filter in the air filter slot. The backward curved or inclined blades of the evaporator fans 26 are well suited to this need, and provide more energy efficient than straight radial blades, which extend straight out from the center of the fan axis. On the other hand, the condenser fans 24 do not need as high of pressure but does require greater overall airflow, as the goal of the condenser fans 24 is to move as much external atmosphere air as possible along the surface of the condenser 16 in order to cool the refrigerant in the condenser 16. The figures illustrate preferred fan blade configurations in the presently preferred air conditioner. One of ordinary skill would understand that the desired performance characteristics of the blades will inform how they are curved and inclined.

The condenser 16 may include a non-rectangular shape in order to match a shape of the housing 20 and achieve higher efficiency. The non-rectangular shape may maximize cross-sectional area within the slot external shape of the air conditioner 10 and take advantage of the full diameters of the condenser fans 26 so that there is no wasted surface area on the condenser 16. In known air conditioners, the condenser is rectangular in shape while the fans have a circular cross-sectional area, resulting in areas of the condenser that does not receive direct airflow from the fans. In addition to being formed with a non-rectangular shape, the present condenser 16 is unique in its arrangement with respect to the condenser fans 24, which are generally located in front of the condenser so that cold outside air is drawn through the condenser in order to cool the refrigerant, but the rectangular profile of such prior art condensers would result in the wasted surface area discussed above. Furthermore, in such an arrangement the dimension of the condenser that has the most significant effect on the efficiency of the condenser as a heat exchanger is the frontal, cross-sectional area measured by the area of the condenser normal to the direction of airflow over the condenser, called face area. Air pressure, caused by the viscous losses of air as it passes through the condenser, is approximately proportional to the square of the velocity of the air over the condenser face area. Therefore, the face area of the condenser has a significant effect on the amount of air a fan may deliver through a heat exchanger. Furthermore, additional face area adds more surface area between the condenser heat exchanger and the air working fluid, which the largest source of thermal resistance in the heat exchanger system. In a larger condenser, each unit volume of air becomes more effective at reducing the condensing temperature of the fluid inside. Regardless of the shape of condenser 16, the major axis 25 of the condenser 16 is in the direction of air intake via condenser fans 24; in other words, the major axis 25 is substantially perpendicular to the evaporator 18.

Accordingly, in known air conditioners in order to increase efficiency of the condenser the face area of the condenser must be increased. However, increasing the face area of a traditional heat exchanger in a window air conditioner is at odds with the goal of reducing the visual frontal area of the air conditioner for a more compact, low profile design that allows the air conditioner to be less obtrusive and easier to handle, install, and uninstall. Instead of reducing the face area of the heat exchanger, such as the condenser or evaporator to satisfy a visual requirement at the expense of the energy efficiency requirements of the air conditioner, the present air conditioner 10 utilizes a unique configuration to create a significant face area of the condenser 16 without merely increasing its dimensions and therefore the dimensions of the entire air conditioner. The present condenser 16 is designed with a slot-shape that is volumetrically optimal, especially when using twin condenser fans 24 to further reduce the overall profile of the air conditioner 10. Furthermore, the C-shape of the condenser 16 allows it to be arranged in a unique arrangement such that the body of the condenser 16 extends substantially perpendicular to the body of the evaporator 18, while wrapping around the sides of the condenser fans 24 to maximize the airflow through the entire face area of the condenser 16. The condenser 16 in conjunction with the other air conditioner 10 components and the body form an enclosed volume in which air driven through the condenser fans 24 can be more effectively used to cool the condenser 16 and achieve higher flowrates and energy efficiency. Further advantages and details relating to the present condenser 16 design and configuration will be discussed in detail below.

The compressor 12, condenser fans 24, and evaporator fans 26 may be at least partially surrounded and/or positioned by the retainer strap 28. The retainer strap 28 may also be the point at which the air conditioner 10 is divided between the portion indoors and the portion outdoors when positioned in a window.

The evaporator 18 preferably includes evaporator piping or tubing 22 that coils through the body, preferably in a serpentine path so as to maximize the path of the refrigerant that flows through the tubing and the evaporator. The body of the evaporator 18 is a heat exchanger, which includes a plurality of fins that may be formed out of a material having good heat transfer properties, such as a highly thermally conductive metal such as aluminum or copper. One of ordinary skill in the art would appreciate that there are a variety of shapes, such as pins, straight fins, or flared fins suitable for heat sink fins. The body of the evaporator 18 may be further configured to include what is commonly known as “offset interrupted fins” or “louvered fins.” In the offset interrupted fins configuration, each “fin” or “plate” of the evaporator body includes a plurality of slits (the “interruptions”) that are generally placed close together at regular intervals. As airflows along the longitudinal direction Y between two fins of the evaporator body, the air enters and exits the plurality of slits/interruptions formed in the fins, which increases heat transfer and causes the airflow to become turbulent, thus ensuring that the cooled air immediately mixes with the surrounding air. To further optimize performance of the evaporator 18 and increase heat transfer, the material between adjacent slits/interruptions in the fins may be stamped to create an “offset,” adjacent offsets being stamped in opposite directions. The offsets interrupt the boundary condition of the airflow and further increase air turbulence, which improves the heat transfer capabilities of the evaporator 18. In the louvered fins configuration, the offsets are at an angle, and adjacent offsets are formed with opposing angles, so that air flowing through one offset out through a slot is forced to change angles before entering an adjacent slot to flow through the next offset, once again increasing turbulence and improving heat transfer.

The fins of the evaporator 18 and condenser 16 heat exchangers are preferably formed from a material having good heat transfer properties, and may be arranged vertically such that air may flow between adjacent fins. The fins are very thin and are arranged vertically along the body of the condenser 16 to maximize the surface area of the fins as external air is blown through the body of the condenser 16 to cool down the refrigerant or other coolant circulating through the condenser tubing.

In existing window air conditioners, positioning the evaporator behind the fan results in “wasted” areas of the evaporator (usually at the four corners) that do not receive direct airflow from the evaporator fan. By taking full advantage of the non-rectangular surface area of the evaporator, the present evaporator assembly configuration is able to utilize a relative smaller evaporator 18, which also contributes to the overall smaller size of the air conditioner 10.

Further advantages of the present evaporator assembly include a reduction in noise. Since there is no direct line of sight from the faceplate of the housing 20 and room air intake grate 34 into the evaporator fans due to their orientation, the sound of the evaporator fans during operation is decreased.

The refrigerant that exits the compressor 12 is in a high-pressure hot gaseous state, and flows through the condenser 16 within the condenser tubing. Like the evaporator 18, the condenser 16 includes a substantially rectangular body that extends and is arranged along the vertical direction, and condenser piping or tubing that coils through the body, preferably in a serpentine path. The body of the condenser 16 is a heat sink having a plurality of fins, which may be arranged like the fins in the evaporator body and configured as “offset interrupted fins” or “louvered fins.” Although the condenser body has a substantially straight profile without any curvature along the horizontal direction, one of ordinary skill in the art would understand that the body of the condenser 16 may also be curved in a way to optimize airflow between the external air drawn in through the external air intake grates, the condenser fans 24, the condenser 16, and the hot air exit vent 38. Furthermore, the exact form and extent of the curvature for the condenser body will be determined based on specific operational parameters desired when taking into account the present teachings.

The connection tubing may be associated with the evaporator tubing and the condenser tubing to allow for the flow of refrigerant from the compressor 12 to the evaporator 18. The connection tubing may be coiled in a serpentine path, and may further include an expansion valve located adjacent to the condenser 16, which may be for example and without limitation a capillary expansion valve. The expansion valve quickly decreases the cross-sectional flow area of the connection tubing and thus drops the pressure of the refrigerant flowing out of the condenser 16, which changes the state of the refrigerant form a high-pressure hot liquid to a low-pressure cold boiling liquid. The compressor 12 may be associated with the evaporator 18 and condenser 16 through a series of compressor tubing, which is preferably arranged in a coiled configuration so as to act as a spring between the compressor 12 and the rest of the components in the air conditioner 10. By acting as a spring, the compressor tubing mechanically isolates the compressor 12 from the evaporator 18 and condenser 16 assemblies, which is desirable because the compressor 12 causes a large amount of vibration during operation, which may damage the other components if not isolated. Where a thermoelectric heat pump is used in place of a compressor 12, the connection tubing between the evaporator 18 and condenser 16 is not required, as the coolant remains within the evaporator tubing and condenser tubing separately. In such an embodiment the thermoelectric heat pump is thermally associated with and arranged between the evaporator 18 and the condenser 16, such that the cold side of the thermoelectric heat pump is thermally associated with the evaporator to cool the coolant contained in the evaporator tubing, while the hot side of the thermoelectric heat pump is thermally associated with the condenser to transfer heat into the coolant contained in the condenser tubing. In such an arrangement, the evaporator and condenser tubing may each be formed as a heat pipe, which is well known heat transfer device, and the coolant used may be, for example and without limitation, a liquid such as methanol or acetone.

As discussed above, the refrigerant that leaves the compressor 12 is in a high-pressure hot gaseous state as it enters the condenser 16, which is cooled by drawing in external ambient air from outside of the space to be cooled, and utilizing air movers (e.g., condenser fans 24) to move the relatively cooler external air through the condenser 16. The external air is drawn in to the back portion of the internal cavity of the housing 20 through one or more external air intake grates 33. The external air intake grates 33 may be located at locations of the housing best suited for ingestion by the condenser fans 24, for example as part of the back plate 32, as will be described in more detail. The external air is expelled towards the condenser 16 to cool the condenser body and the refrigerant circulating within the condenser tubing. As the external air blows through the body of the condenser 16, the high-pressure hot gaseous refrigerant flowing through the condenser tubing is in cooled liquid state when it leaves the condenser 16. The external air blown through the body of the condenser exits the face of the condenser body as hot air through the hot air exit vents 38, which may be located at the back portion of the housing 20 as grates or vents aligned with the body of the condenser 16, as shown in FIG. 3. Preferably, the hot air exit vents 38 takes up a most of the back of the housing 20.

The interior face of the air conditioner 10 has a face plate 30 that serves as a handle 36, a control knob 52 (shown in FIG. 1), and a light pipe or LED display. The housing 20 includes the face plate 30 and a back plate 32. The face plate 30 may be positioned in front of the evaporator 18 while the back plate 32 is positioned behind the condenser 16. The face plate 30 may be a shell component configured to receive a portion of the evaporator 18. The face plate 30 preferably includes a room air intake vent 34 which may have a grill with perforations for safety and to visually obstruct the internal components. The room air intake vent 34 is formed all around the handle 36. Instead of a visible grate, the vent 34 may be integrated into the face plate 30 and handle 36 combination design which provides efficient functionality while being aesthetically pleasing. The vent 34 may be formed along the perimeter of the handle 36, and sized to accommodate a user's fingers to provide additional space around and behind the handle 36 so that the handle 36 can be easily grasped. The face plate 30 may also include a space for a control knob (shown in FIG. 26). The back plate 32 is preferably a grill including perforations for acting as a hot air exit vent.

The air conditioner 10 may also include an electronics enclosure 40 for, for example, electronics and a capacitor, positioned adjacent to the evaporator 18 and configured to fit within the face plate 30. The electronics are positioned so that they can be manipulated by a control knob protruding from the face plate 30. The capacitor is electronically connected to the compressor 12.

The compressor 12 is centrally mounted between the two sets of fans 24 and 26 which may be symmetrically arranged on opposing sides of the compressor 12. This configuration inside of the housing 20 provides a balanced design and enables a compact arrangement of the components. Another advantage of the centrally located compressor 12 is that it can be mounted using horizontal mounting fixtures (e.g., mounting feet 46 shown in FIGS. 4, 9, 25, and 26) without modification, as will be described in further detail below. This also helps reduce vibrations in the unit, as the mounting fixtures can incorporate shock absorbers. The centrally mounted compressor 12 may be arranged such that its body is substantially parallel to the rotational axis of the condenser and evaporator fans 24, 26, as shown in FIGS. 4 and 9, or may be rotated such that the body of the compressor 12 is substantially perpendicular, i.e. approximately 90°, relative to the rotational axis of the condenser and evaporator fans 24, 26, as shown in the alternate embodiment shown in FIGS. 32-45.

FIGS. 1, 3, 6, and 8 illustrate views of the air conditioner 10 and its internal components that are helpful for understanding the airflow directed through the heat exchangers. As shown, room temperature air enters through the room air intake grates 34 formed in the face plate 30, preferably around the handle 36, and is then directed though the evaporator 18 to be cooled and expelled by the evaporator fans 26 into the room through a cold air exit vent 44. External air is drawn in by the condenser fans 24 and expelled through the hot air exit vent 38 of the back portion of the housing 20.

The positioning of the cold air exit vent 44 on the top portion of the housing 20 reduces re-ingestion of cold air back into the room air intake grate, thus increasing the efficiency and effectiveness of the present air conditioner 10. In known air conditioner units, the cold air exit vent is usually located on the front of the housing, such as near the top edge of the face plate. As cold air is expelled through such a cold air exit vent, the air “sinks” in the downward direction due to the higher density of cooler air, and in the process of sinking some of the already-cooled air is re-ingested into the air conditioner through the room air intake grate located on the front of the housing, resulting in inefficiencies for the system. The present air conditioner 10 addresses this issue by positioning the cold air exit vent 44 on the top portion of the housing at a sufficient distance away from the face plate 30 and room air intake grate 34 located at the front of the housing 20 and utilizes the curved turning vanes to expel the cooled air upwardly at an angle into the room.

FIGS. 4-21 provide additional views of the internal components of the air conditioner 10, including additional components of the preferred housing 20, including a lower manifold 48 shown in FIGS. 12-15. The lower manifold 48 forms a bottom internal portion of the housing 20 and may include a clam shell design which cooperates with an upper manifold 50 (shown in FIG. 9) to surround and support the internal components of the air conditioner 10.

The lower manifold 48 (and upper manifold 50) are preferably formed as separately-molded pieces. Conventional air conditioning units usually include a bottom plate (instead of a manifold) or a bottom tray that all major components are affixed to and a metal sheet enclosure which provides less than ideal structural integrity for the unit. The clam shell manifolds 48, 50 combine to hold internal components in place while adding structural integrity to the overall unit.

FIG. 10 illustrates an isometric view of the air conditioner 10 with the upper manifold 50 in place and connected to the lower manifold 48 to form the internal support portion of the housing 20. The interconnected manifolds 48, 50 form the clam shell manifold assembly which forms a duct around the four fans 24, 26 to direct air flow appropriately to enhance cooling density of the heat exchanger portions of the condenser 16 and evaporator 18. The upper manifold 50 covers the fans 24, 26 but an opening is created in both the lower and upper manifolds 48, 50 to accommodate the C-shaped condenser 16, with two reliefs formed on the underside of the lower manifold 48 to act as close outs for the condenser 16 coils when assembled, so that together the body of the condenser 16 and the lower and upper manifolds 48, 50 form a substantially enclosed volume.

FIGS. 1-5 contain various views which illustrate the full external housing 66 of the housing 20. The external housing 66 forms an outer most protective portion of the air conditioner 10 and extends between the face plate 30 and the back plate 32. The retaining strap 28 may be configured to protrude from the external housing 66 and includes window frame adapter fastening elements to be used to secure the air conditioner 10 to a window opening, receptacle, or adapter when installed. The external housing 66 further includes the hot air exit vents 38 which are aligned with the body of the condenser 16 to facilitate the condenser air flow out of the housing 20 to expel hot air. The external air intake grate 33 may be formed along substantially the entire area of the back plate 32 in order to maximize and enhance air flow to the condenser fans 24 to ensure sufficient air flow to effectively cool the condenser 16.

In use, the interior room air is drawn in through the room air intake (at grate 34) and is cooled by the relatively colder surfaces of the fins of the evaporator body due to the cold boiling liquid refrigerant flowing through the evaporator tubing. As the cooled interior room air exits the back of the evaporator body, the cooled air is guided upwards and back into the interior of the room or building by an air guide assembly through the cold air exit vent 44 located at the top portion of the housing. The thermal energy (i.e. heat) from the cooled interior room air IA is transferred into the refrigerant that flows through the evaporator tubing of the evaporator, which is in turn warmed from a low-pressure cold boiling liquid into a low-pressure cold gas as the refrigerant flows from the evaporator 18 through the accumulator 14 and into the compressor 12 to be pressurized and heated. The accumulator 14 ensures that any liquid left in the refrigerant is removed before the refrigerant enters the compressor 12, so as not to damage the compressor 12 when the gaseous refrigerant is pressurized and heated.

FIGS. 7-15 further illustrate the manifold assembly 90, including the lower manifold 48 and the upper manifold 50. The manifold assembly is a clamshell design with the lower and upper manifolds 48, 50 that are singular molded parts which reduce the overall part count and improve stiffness of the structural design. Each of the lower and upper manifolds 48, 50 may be a single injection molded part, which reduces the part count for the entire air conditioner assembly and improves overall stiffness. When connected to each other, the manifolds 48, 50 include a wall 70 which divides the evaporator portion from the condenser portion of the air conditioner 10. The wall 70 includes openings 72 for the motors of the sets of air movers (formed by fans 24, 26) and receptacles 74 for the retaining strap 28. The lower manifold 48 includes various integral compartments for receiving the internal components of the air conditioner 10. The lower manifold 48 may include supports for the compressor mounting feet 46. The upper manifold 50 may include integral compartments which align and combine with the lower manifold 48 to form appropriate ducts and air guides around the fans to direct the air through the evaporator portion and condenser portion. The manifolds 48, 50 also provide convenient points of fixation for the various components.

Returning to the unique shape and configuration of the present condenser 16, which in combination with the other components of the air conditioner 10 addresses the disadvantages and issues in known air conditioners to achieve higher airflow and energy efficiency while maintaining a compact and low-profile design. By bending the condenser 16 into a C-shape design to approximate the perimeter of the air conditioner and maximize available surface area for the condenser fans 24, a significantly larger face area of the condenser 16 is created which reduces air pressure and allows more air to be delivered by the same fan system. Furthermore, the location of the condenser fans 24 promotes even airflow of air over the condenser 16. In the case of air being blown into the inside surface of the condenser 16, the use of an external ring 54 on each of the individual condenser fans 24 (as shown in FIGS. 18-21) allows condensate water from the evaporator 18 to be slung on the edge of the condenser 16, as well as the inside surface of the condenser 16. The rings 54 are also strategically positioned downstream of the airflow and outside of the fan duct. This is beneficial to the compressor 16 where any of the condensed water that does not make it onto or into the condenser 16 is slung onto the compressor, further reducing its working temperature, thus improving its efficiency. This additional latent condensate cooling of the condenser 16 combined with the significant airflow over the condenser 16 form a potent combination that results in a modern, high-efficiency air conditioner 10 which reducing the visual area of the air conditioner by more than 30%, without sacrificing performance.

If condensate cannot be used for further cooling of the condenser 16, such as in the case of microchannel condensers, which are sensitive to corrosive ionic impurities in the condensate water, the condenser fans 24 may pull air from inside the internal plenum of the condenser 16, and blow the heated air out of the back of the air conditioner 10 through the back plate 32. In both airflow cases, the bent shape of the condenser 16, which follows the perimeter of the air conditioner 10 in a rounded shape, offers significant face area of the heat exchanger, while limiting the visual size of the air conditioner. Furthermore, the C-shaped contour of the condenser 16 follows the perimeter of the condenser fans 24, which further reduces the visual profile of the air conditioner 10.

An additional feature of the C-shaped of the condenser 16 is that the open area of the condenser 16, in this case located at the bottom middle of the air conditioner 10 as shown in FIG. 21, can be dedicated to the placement of the feet 46 of the compressor 12 where the compressor 12 is mounted so that its body is aligned with the rotational axis of the fans 24, 26. The open area also allows a path for water/condensate to flow to the back of the air conditioner 10, to be collected in a trough which the condenser fans 24 can then spray back onto the condenser 16 for further cooling. Alternatively, the mounting feet 46 of the compressor 12 can also be provided fore and aft of the compressor 12 and the condenser 16 if space dictates, which leaves additional space for water/condensate to travel to the desired location. Furthermore, with certain configurations, portions of the condenser 16 can be submerged in the condensate water to more fully transfer heat and to evaporate the water, which will extract the latent heat from the condensate and improve the heat transfer capability of the condenser 16.

Whether the condenser fans 24 blow into the plenum formed by the condenser 16 or out into the ambient air behind the window air conditioner 10, the design also has the added benefit of improving the inlet conditions of the condenser fans 24 by creating straight airflow velocity vector as air enters the fan. Since the condenser fans 24 are relatively unobstructed both upstream and downstream of the fans (whether configured as axial or crossflow fans), this has the added benefit of improving fan performance in terms of airflow, but also in terms of the sound generated by the fan, since inlet vortexes generated by poor inlet conditions interact with the fan blades in ways that are deleterious to both acoustics and fan efficiency. In this manner, the overall noise of the air conditioner 10 can be reduced leading to a better user experience.

The present air conditioner 10 having a C-shaped condenser 16 arranged over and around the condenser fans 24 can also be implemented through various alternate embodiments, which may be used to address constraints dictated by a variety of conditions, including the physical size of the air conditioner 10, the system layout or configuration, the control of costs of components, or the capacity required of the air conditioner 10 or cooling system. In the following description, all heat transfer mechanisms, including gases, liquids, or other mechanisms for removing or transferring heat are implied when the word air is used or the word or words airflow or air flow are used.

An alternative approach to handling air flow through the condenser 16 can be addressed with variations on the fan design, for situations such as when a sharper turn is required for the air to exit through the condenser 16, when higher pressure is required to get the necessary air volume through the condenser 16, or when a varied flow through different sections of the condenser 16 is warranted for efficiency. Size considerations may permit or dictate further fan options, such as when the condenser 16 is large enough to partially or completely encircle the fan enclosure. In the case where limited distance is available for the condenser fans 24, a centrifugal fan or radial fan or mixed flow fan can be placed inside each curved portion of the C-shaped condenser 16, allowing the natural action of the centrifugal fan's right angle flow from intake to exhaust to draw air into the end of the fan and expel it directly into the body of the condenser 16. Additionally, if conditions dictate higher pressure or more evenly controlled flow over the surface of the condenser 16, there are multiple alternative fan and enclosure designs as fan, duct, and straightening vane combinations will enable control the airflow more precisely to extract as much heat from the refrigerant as it passes through the condenser 16. FIGS. 22B and 23 illustrates alternative fan designs that may be utilized in the present low profile air conditioning system, and the air flow characteristics associated with each type of fan design.

Combination fan designs such as mixed flow fans or crossflow fans can be used with a variation to their typical axial flow implementation, where the use of different fans can provide higher pressure and lower volume flow. In the case of a mixed flow fan, where the natural pattern of the air as the fan accelerates it is to angle outward as shown in FIGS. 22B and 23. Rather than converting this flow back into a straight flow as typically done where mixed flow fans are used, a partial duct may be used to efficiently create a higher pressure while increasing efficiency by not redirecting the angled outflow and using it to move the air directly across the heat transfer surfaces of the condenser 16. Mixed flow fans also typically provide an outlet flow that is nominally at a 45 degree angle to the fan axis of rotation, which provides a more direct path of airflow to the face of the condenser coil, as shown in FIG. 22B in comparison to the airflow path of an axial fan as shown in FIG. 22A. Fix flow fans are thus less dependent on the housing and manifold design and the tip to housing clearance to produce efficient airflow, and therefore can achieve additional efficiencies. In the alternate embodiment shown in FIG. 22B, the mix flow fan is positioned partially within the surrounding C-shaped condenser coil along the axial direction, and therefore also allows the overall length of the air conditioner 10 to be reduced in comparison to the arrangement of the axial fans shown in FIG. 22A.

Additional improvements to the efficiency of condenser 16 are possible by establishing an uneven flow of the refrigerant through the condenser 16, or an uneven profile of the condenser 16 to better match the uneven air flow or fluid flow that is characteristic of any air conditioning or other heat transfer system. As air or a fluid is accelerated, the inertia of the moving air or fluid makes it impossible to turn the air or fluid quickly enough to evenly pass through all of the heat transfer area of the condenser 16. In a design where the condenser 16 has headers on each end, differing tube sizes, tube lengths, fin sizes or contours, fin configurations, or surface treatments can essentially throttle the flow of the heat transfer air or fluid to maximize the efficiency of the heat transfer for specific areas of the condenser 16 due to uneven flow conditions.

Making further reference to the illustrative drawings, as shown in FIGS. 4-10, the C-shaped condenser 16 is arranged between the front evaporator fans 26 (shown as centrifugal fans in this embodiment, but can also take the form of crossflow or mixed flow fans) and the back condenser fans 24 (shown as axial fans in this embodiment, but can also take the form of crossflow or mixed flow fans), and oriented such that the body of the condenser 16, specifically the major axis 25 of the condenser, is substantially perpendicular to the body of the evaporator 18. The condenser fans 24 are arranged within an intake duct, and located behind the condenser 16. The curved sides of the condenser 16 match the profile of the axial condenser fans 24, and allow the condenser 16 to be associated with a foam wall 56 as shown in FIG. 8 that separates the condenser 16 and condenser fans 24 from the front of the air conditioner. A faring and other elements of the upper and lower manifolds 48, 50 are further associated with the condenser 16 to form an enclosed volume, which is sealed against the air from the cold evaporator side of the air conditioner 10, and which creates a high-pressure zone inside the condenser 16 such that when outside air in drawn through the condenser fans 24, the air is forced through the coils of the condenser 16 to effectively cool the condenser and coils. FIG. 14 further illustrates a condenser closeout wall 58 that can be part of the manifolds 48, 50, or a separate component associated with the manifolds 48, 50 and condenser 16, which closes out the sides of the condenser 16 to prevent air from bypassing the fins of the condenser 16 in the high-pressure zone.

FIGS. 11-13 illustrate the unique water/condensate management system of the present low profile air conditioner 10 design, as portions of the manifold 48, 50 are designed to help direct the water or condensate that results from the refrigeration cycle in a manner that is most efficient. FIG. 11 show the flow of water or condensate from the front of the air conditioner (the “cold side”) through a central water channel into the back of the air conditioner (the “hot side”) in the enclosed volume created by the C-shaped condenser 16 and manifold 48, 50. The water flows into the rear water channels, and as shown in FIG. 12 can drain there once through the openings for the condenser fans 24 once a maximum level is reached. However, much of the water or condensate will evaporate due to the heat in that enclosed volume on the hot side of the air conditioner 10. As further shown in FIG. 12, a front wall of the manifold 48, 50 adjacent to the centrifugal evaporator fans 26 includes a small opening, which allows water or condensate to enter the central water channel. This opening is designed to let water through without air from the cold side of the air conditioner 10 being pulled through as well, which allows the high-pressure enclosed volume created by the condenser 16 to operate as described above for maximum air flow and energy efficiency. As shown in FIG. 13, the back of the condenser volume created by the enclosure or intake duct around the condenser fans 24 retains any unevaporated water or condensate that is slung out by the slinger ring 54 onto the condenser fans 24 themselves.

FIGS. 16-21 illustrate the refrigeration components of the present air conditioner 10, and further highlight the unique structure and configuration of the condenser 16. The sling rings 54 are also shown in more detail in FIG. 18, which allows collected water or condensate to be “slung” onto the blades of the condenser fans 24 during operation. FIGS. 25-31 further illustrate the C-shaped condenser 16 without the foam wall 56, lower and upper manifolds 48, 50, or other housing 20 components to better illustrate the placement of the condenser 16 with respect to the evaporator 16 and fan assemblies.

One of ordinary skill in the art would appreciate that various aesthetic changes may be made to the present air conditioner without departing from the inventive features and components discussed herein.

Other aspects of the present low profile air conditioner design are set forth in U.S. patent application Ser. No. 15/784,768 for “Air Conditioner and An Air Conditioner Housing,” which in turns claims the benefit of Provisional Application No. 62/408,811, which are hereby incorporated by reference.

Although the preferred configuration of the window air conditioner in the present application has been described with the compressor being arranged along a direction that is perpendicular to the direction along which the bodies of the evaporator and condenser extend, FIGS. 32-45 illustrate the same efficiencies and advantages described above by reconfiguring the components such that the compressor is rotated 90 degrees to extend along the same direction that the bodies of the evaporator and condensers extend. Furthermore, while the evaporator and condenser fan assemblies have been described with each set of evaporator and condenser fans being driven by a single motor, so that only two motors are utilized in the window air conditioner, different combinations of numbers of fans and motors may be utilized to achieve the same function. For example and without limitation, each fan may be driven by an individual motor, so that four separate motors are utilized. While this would increase the number of components and overall cost and weight of the window air conditioner, it presents advantages in that each fan can be individually optimized to operate at different speeds, in order to maximize the airflow through each heat exchanger. As a further example, the two centrifugal evaporator fans may be driven by a single motor, while the two axial condenser fans may each be driven by an individual motor, so that three total motors are used to drive a total of four fans. In addition, the direction along which the centrifugal fans and axial fans rotate may be reconfigured without departing from the spirit of the present application. In the embodiment described above, each set of centrifugal and axial fans are driven by a single motor along a rotational axis that is substantially parallel to the direction that the compressor is arranged. Given this arrangement, the centrifugal and axial fan of each set rotates in the same direction about the same rotational axis. However, in alternate embodiments where the centrifugal fans are each driven by its own motor, or are driven by the same motor separate from the axial fans, the centrifugal fans may be arranged so that they rotate around a different axis, which is substantial perpendicular to the axis of rotation of the axial fans.

Alternatively, each centrifugal evaporator fan 26 can be driven by its own motor 42, which would allow each evaporator fan to operate separately at its own fan speed, and along its own rotational axis which may be offset from the rotational axis of the other evaporator fan. Having the two evaporator fans 26 arranged along slightly offset rotational axes may be desirable in order to meet space constraints within the window air conditioner housing, so that other components may be arranged near the fans, or can be done to optimize the desired airflow and pressure created by the evaporator fans. In this alternate embodiment, each axial condenser fan 24 is driven by its own motor 42, which can be incorporated into the fan itself and integrated within the fan hub. The axial condenser fans 24 each rotate around an axis that is substantially perpendicular to the rotational axis of the centrifugal evaporator fans. As discussed above, the separately operated axial condenser fans 24 can each rotate at a different fan speed, and may be arranged with respect to the condenser 16 and the rest of the assemblies to maximize airflow and pressure to achieve desirable efficiencies and flow rates.

FIGS. 32-47 illustrate one such alternate embodiment 100 that utilizes a different compressor configuration, different type of fans for the condenser fans 124 and evaporator fans 126, and forming the condenser 116 as two separate C-shaped portions instead of one single continuous body, and different axes of rotation for the condenser and evaporator fans 124, 126, each driven by its own motor 142, while still achieving the advantages described above with respect to the present window air conditioner. As shown in FIGS. 32-35, each of the condenser fan 124 and evaporator fan 126 are formed as crossflow fans, which draw air from inside and outside of the room in the same manner as described above when the evaporator fans were formed as centrifugal fans and condenser fans formed as axial fans. The compressor 112 is still arranged between the evaporator 118 and condenser 116, but is now oriented such that the body of the compressor 112 is substantially perpendicular to the direction along which the body of the evaporator 118 extends. Furthermore, instead of being formed as one continuous piece, the condenser 116 is formed as two separate C-shaped portions, as shown in FIGS. 32-33 and 44-45, with the ends of each C-shaped portion associated with a structural element of the housing 120 of the air conditioner 100, which in combination with the condenser 116 and other elements of the housing 120 still forms an enclosed high-pressure volume. Forming the condenser 116 in this manner allows the air conditioner 100 to be easier to assemble, as the two separate C-shaped portions of the condenser 116 can be each independently placed around the centrally located compressor 112 and other components. The crossflow evaporator fans 118 are still arranged in front of the compressor 112 but behind the evaporator 118, while the crossflow condenser fans 124 are still arranged behind the compressor 112 and condenser 116, such that as shown in FIGS. 46 and 47 the evaporator fans 126 suck room temperature air in through the evaporator 118 to be cooled and expelled through the evaporator fans 126, while outside air is drawn in by the condenser fans 124 and blown through the condenser 116 to cool down the refrigerant. This alternate arrangement of the internal components still maintains the low profile of the window air conditioner 100, where the total height of the unit is determined by the maximum diameter of the compressor, evaporator fans, and condenser fans, all of which are substantially the same as each other. The unique shape of the condenser 116 formed from two C-shaped portions maximizes the face area and air flow, while maintaining the small frontal visible area of the air conditioner for a compact profile. As shown in the air flow paths illustrated in FIGS. 46 and 47, the evaporator fan 126 formed as a crossflow fan rotates along an axis that is substantially perpendicular to an axis along which the evaporator 118 body extends, and draws warm inside air into the housing 120 of the air conditioner 100 to be cooled by the evaporator 118, and then expels the cooled air upwards through the cold air exit vent 44 located at a top portion of the air conditioner 100. The condenser fan 124, which is also formed as a crossflow fan, rotates long an axis that is substantially perpendicular to the rotational axis of the evaporator fan 126, and draws in outside air along the body and curved sides of the condenser 116 to cool the refrigerant circulating within the body of the condenser 116, and as shown in FIG. 47 after the outside air is pulled through the condenser 116 it is ejected downwards by the condenser fan 126 through the hot air exit vent 138 located at a back portion of the air conditioner 100.

Accordingly, even though the figures in the present application show embodiments utilizing a certain combination of motors and fans, and specific arrangement of the horizontally mounted compressor with respect to the fans, and forming the non-linear condenser as two separate portions instead of one single continuous body, such configurations should not be interpreted as being a limitation on the present invention. 

What is claimed is:
 1. An air conditioner comprising: a housing, with at least a top, a bottom and two sides that defines an interior space including: at least one evaporator air mover; an evaporator that is positioned in front of the at least one evaporator air mover; at least one condenser air mover; and a non-linear condenser that is positioned behind the at least one evaporator air mover with a body of the non-linear condenser extending substantially perpendicular to a body of the evaporator.
 2. The air conditioner of claim 1 wherein the condenser is C-shaped.
 3. The air conditioner of claim 2, wherein the C-shaped condenser is positioned with an open portion facing one of the bottom and top of the housing and curved portion extending toward the two sides.
 4. The air conditioner of claim 2, wherein the at least one condenser air mover has an airflow path that extends through the body and two side walls of the C-shaped condenser.
 5. The air conditioner of claim 2, wherein the condenser comprises two separate C-shaped condensers.
 6. The air conditioner of claim 2, wherein the at least one condenser air mover comprises two air movers with blades that define a perimeter, and the non-linear condenser has at least one end portion that surrounds the perimeter defined by at least the blades of one air mover and each positioned within the perimeter defined by the respective air mover.
 7. The air conditioner of claim 6, further comprising a trough that is positioned proximate an open portion of the non-linear condenser and configured to guide condensate to the at least two air movers.
 8. The air conditioner of claim 6, further comprising a front wall positioned behind the evaporator air mover, a manifold associated with or formed as part of the housing, which front wall and manifold are associated with the C-shaped condenser to create a substantially enclosed volume through which air can only flow through the two air movers.
 9. The air conditioner of claim 1 wherein the condenser is curved to partially circumscribe airflow defined by the at least one condenser air mover.
 10. The air conditioner of claim 1 wherein the at least one condenser air mover is configured to spray condensate onto the condenser.
 11. The air conditioner of claim 1, further comprising an external ring arranged substantially coaxially with the at least one condenser air mover to allow condensate water to be sprayed onto the condenser.
 12. The air conditioner of claim 1, further comprising: a pump that is positioned between the condenser and the evaporator and circulates a refrigerant between the condenser and the evaporator; and, the at least one condenser air mover comprises two separate condenser air movers positioned so that the pump is located between the two condenser air movers and the pump is mounted to the bottom of the housing at an open portion of the non-linear condenser.
 13. The air conditioner of claim 12 wherein the evaporator is configured to produce a condensate and the two condenser air movers are positioned to direct the condensate onto the condenser.
 14. The air conditioner of claim 13 wherein the housing comprises at least one condensate flow channel configured to direct condensate from a first portion of the interior space of the housing to a second portion of the interior space of the housing, wherein the second portion is a substantially enclosed volume defined by the condenser, a thermal wall, the bottom of the housing, and the two condenser air movers.
 15. A non-linear condenser for an air conditioner comprising: a condenser housing having a major axis; and a plurality of coils positioned in the condenser housing for guiding a flow of refrigerant; wherein the condenser housing is at least partially curved along the major axis.
 16. The non-linear condenser of claim 15, wherein the housing has a C-shape and the curvature of the housing occurs at each end of the housing.
 17. The non-linear condenser of claim 15, wherein the condenser housing is comprised of two separate housings, each having a C-shape.
 18. A method of dissipating heat in a condenser of an air conditioner, comprising the steps of: providing an air conditioner having an evaporator, at least one fan, and a condenser positioned downstream of the fan between the fan and evaporator; forming a water condensate via the evaporator; directing the water condensate to the at least one fan; and dispersing the water condensate onto the condenser via the fan.
 19. The method of claim 18, further comprising the steps of: providing a partition wall between the evaporator and the condenser, the partition wall having an inlet that allows water condensate from the evaporator to flow through but does not allow air to flow through; providing a housing arranged around the evaporator, at least one fan, condenser, and partition wall, the housing having a top, a bottom, and two sides; and forming a substantially enclosed volume between the partition wall, the bottom of the housing, the condenser, and the at least one fan.
 20. The method of claim 18, further comprising the step of providing the condenser as two separate condenser bodies, each having a C-shape. 